Bulk bag with full perforation

ABSTRACT

A novel bag for holding, transporting, and pouring a bulk product is provided. The bag comprises a perforated section extending the majority of the way (and preferably the entire way) horizontally across the bag. The bag can be opened by tearing along the perforations and separating the resulting two sections of the bag. The bag is typically formed of plastic, and can be used for salt, animal food, and other pourable products.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is broadly concerned with the field of bags forholding pourable products such as salt, and more particularly bagshaving a perforated section that extends substantially, and preferablyentirely, horizontally across the bag, for removal and pouring of theproduct from the bag.

2. Description of the Prior Art

Bag are commonly used to hold and transport pourable products (i.e.,products comprising numerous small pieces). Such products include saltcubes or pellets, animal food, flour, and sugar, to name a few. Thesepourable products are typically sold in large quantities (e.g., 30-50lbs.) and in bulk sizes that are difficult for the average person tohandle. Even more difficult than carrying these bags is pouring theproduct from the bulky bag. That is, the consumer must open the bag,attempt to pick up the very heavy bag, and carefully pour the product ina controlled manner. This often results in spilling of the product,which goes from not coming out at all to rapidly falling from the bagand outside of the target area. There is a need for a bag that can bemore easily opened at the point of use, as well as more easily pouredwith minimal or no spillage.

SUMMARY OF THE INVENTION

In one embodiment, the invention provides a bag for holding a pourableproduct. The bag comprises front and back panels comprising first andsecond end portions presenting respective outermost edges and first andsecond side portions presenting respective outermost edges. The frontand back panels and the end and side portions cooperate to form achamber for holding the pourable product. There is a width “W,” definedas the shortest distance between the respective outermost edges of thefirst and second side portions. The perforations extend from at leastone of the respective outermost edges of the first and second sideportions at a distance of at least about 50% of “W,” towards the otherof the respective outermost edges of the first and second side portions.

In another embodiment, a method of using the above inventive bag isprovided. The method comprises tearing the bag at the perforations tocreate an opening, and causing the pourable product to exit the bag fromthe opening, preferably by tilting the bag.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. (FIG. 1 is a front elevation view of a bag according to theinvention;

FIG. 2 is a rear elevation view of a bag according to the invention; and

FIG. 3 is a front elevation view illustrating the dimensions of a bagaccording to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 1-3, a bag 10 is illustrated. Bag 10 includes afront panel 12 and a back panel 14. As shown, front and back panels12,14 are flat to demonstrate their respective shapes before beingfilled with product. Front panel 12 and back panel 14 share a first endportion 16 and a second end portion 18.

Front panel 12 and back panel 14 further share a first side portion 20and a second side portion 22. First and second end portions 16, 18 andfirst and second side portions 20, 22 present respective outermost edges24 a-d, which define an outer boundary or periphery 26 of the bag 10.Outermost edges 24 a and 24 b oppose, and are substantially parallel to,one another, while outermost edges 24 c and 24 d oppose, and aresubstantially parallel to, one another. Furthermore, outermost edges 24c and 24 d are substantially perpendicular to outermost edges 24 a and24 b.

Each of the first and second end portions 16, 18 intersects with firstand second side portions 20, 22 at corners 28 a-d. Front and back panels12, 14, first and second end portions 16, 18, and first and second sideportions 20, 22 cooperate to form a chamber for holding a pourableproduct.

First end portion 16 comprises a first horizontal seam 30 spaced apartfrom outermost edge 24 a, thus forming a flap 32 in first end portion16. First horizontal seam 30 has a thickness of from about 1/16 inch toabout ¼ inch (and more preferably about ⅛ inch) and is substantiallyparallel to outermost edge 24 a. Flap 32 comprises a handle 34 formedtherein. Handle 34 comprises a patch 36 that is heat-sealed to the flap32. Patch 36 could be heat-sealed on either side of the flap 32 (i.e.,on front panel 12 or on back panel 14), or on both sides if extrastrength is required. Patch 36 can be any material typically used forbags carrying bulk products, including plastics such as linear lowdensity polyethylenes (LLPDE). A C-shaped grip 38 is formed throughpatch 36 and flap 32 to form an opening, through which a user may placehis or her fingers during carrying, pouring, etc. Outmost edge 24 a offirst end portion 16 is bisected by centerline 40 (see FIG. 3). In apreferred embodiment, handle 34 is positioned such that some portion ofthe grip 38 falls upon the centerline 40. Also, while it will beappreciated that the handle 34 is integrally formed with the bag 10 (andparticularly with flap 32) as described above, one may also substitutean integrally formed handle with a separately formed handle that is thenphysically attached to the bag 10.

The bag 10 further comprises perforations 42 in front and back panels12,14. Perforations 42 provide an area where the front and back panels12, 14 can be separated, creating an opening for pouring of product fromthe bag 10. Ideally, perforations 42 form a pattern that is linear innature, and substantially parallel to outermost edges 24 a, 24 b andsubstantially perpendicular to outermost edges 24 c, 24 d. The figuresdepict perforations 42 extending from outermost edge 24 c to outermostedge 24 d, however, in some embodiments, the perforations 42 do notextend entirely across the width “W” of the front and back panels 12,14, However, it is preferred that the perforations 42 extend at leastabout 50% of “W,” preferably at least about 75% of “W,” and morepreferably about 100% of “W.” Furthermore, although the figures show theperforations 42 at a distance “D³” from outermost edge 24 b, it will beappreciated that the perforations 42 can be positioned anywhere alongthe length “L¹” of the front and back panels 12, 14, providedperforations 42 are at least about 0.5 inches, and preferably at leastabout 1 inch, from first horizontal seam 30 and outermost edge 24 b.

The bag 10 preferably has a side panel 44. Side panel 44 is essentiallya lay-flat fold whose width is defined by a turn axis 46. Side panel 44allows for expansion of the bag upon filling with the pourable product.

Referring to FIG. 3, several dimensions of the inventive bag 10 havebeen defined. The ranges for those dimensions are shown in Table 1.

TABLE 1 Preferred Bag Dimensions Dimension Broad Range Preferred RangeMost Preferred Range from FIG. 3 (inches) (inches) (inches) L about 20to about 35 about 24 to about 30 about 26 to about 28 W about 10 toabout 24 about 14 to about 20 about 15 to about 18 D¹ about 2 to about3.5 about 2.2 to about 3 about 2.4 to about 2.8 D² about 2 to about 4about 2.5 to about 4.5 about 2.9 to about 3.2 D³* about 0.5 to about 10about 2 to about 8 about 4 to about 7 L¹ about 17 to about 30 about 20to about 28 about 22 to about 26 L¹/D³* about 2 to about 15 about 2 toabout 10 about 3 to about 7 *Distance from either outermost edge 24b orfirst horizontal seam 30. **Unitless

The inventive bag 10 can be manufactured by various methods, but thepreferred method is described herein. First, a tube or sleeve of plasticis cut to the desired length (represented by “L” in FIG. 3). The plasticof which the inventive bag is formed can be any material typically usedto form bags carrying bulk products. The plastic should be flexible andstretchable so that the bag collapses as the bulk product is poured fromthe bag. Preferably, the plastic of which the bag is formed stretchesfrom about 1 to about 2 times at yield, and more preferably about 1.5times at yield. Furthermore, it is preferred that the bag be formed of aplastic that stretches at least about 4 times, preferably at least about5 times, and more preferably from about 5 to about 7 times at its breakpoint. Thus, the preferred plastic has an ASTM D882 percent elongationof from about 200% to about 800%, preferably from about 400% to about700%, and more preferably from about 500% to about 650%. The thicknessof the preferred plastic is from about 2 mil to about 14 mil, preferablyfrom about 4 mil to about 10 mil. and more preferably from about 6 milto about 8 mil. The most preferred material is LLDPE.

A heat seal is then applied at first end portion 16 in order to formhorizontal seam 30. A film (typically having a 10-mil thickness) isheat-sealed to flap 32 to form patch 36. C-shaped grip 38 is then cut(e.g., die-cut) through the patch 36 and flap 32, thus forming handle34, which serves as the primary carrying handle. The perforations 42 canbe added at this time according to conventional methods.

The manufactured bag can then be stored until needed, or immediatelyfilled and sealed. Either way, after the bag 10 is filled to the desiredlevel, a final heat seal is applied at second end portion 18 to createsecond horizontal seam 44, making the filled bag 10 ready fordistribution. It will be appreciated that the inventive bag 10 can beused to transport and store numerous types of pourable products,including cubes, pellets, tablets, powders, compacted pieces, and/orgranules of those selected from the group consisting of: salt (e.g.,water softening, pool treatment, deicing, etc.); animal food (e.g., birdseed, grain, dog or cat food); bulk flour or sugar; cement; seed (e.g.,grass seed) and other lawn and garden products; fertilizers; ice; sand;rice; spices; soil (including soil mixtures); pesticides (e.g., fire anttreatments); industrial chemicals; mortar; plaster; marble dust; stones(including pebbles and gravel); and constructions products. Suchproducts will typically cause the bags to weigh from about 20 lbs. toabout 100 lbs., and more typically from about 40 lbs. to about 60 lbs.

In use and before pouring, a user would tear the front and back panels12, 14 at perforations 42 in order to separate (or at least partiallyseparate) strip 48 from the remainder 50 of bag 10. It will beappreciated that this allows for easy pouring of the product from thebag 10.

This controlled pouring allows for fairly exact dispensing of theproduct, while preventing spillage and waste of the product. This typeof opening is particularly advantageous in situations where the bag isbeing poured into a large opening. The user can just lay the bag on topof the large opening and use both hands to tear perforations 42 andseparate strip 48 from remainder 50, thus avoiding the need to hold andtilt a heavy bag during product removal.

We claim:
 1. A bag for holding a pourable product, said bag comprisingfront and back panels each comprising: first and second end portionspresenting respective outermost edges; first and second side portionspresenting respective outermost edges, said front and back panels andsaid end and side portions cooperating to form a chamber for holding thepourable product, there being a width “W,” defined as the shortestdistance between the respective outermost edges of said first and secondside portions; and perforations extending from at least one of saidrespective outermost edges of said first and second side portions adistance of at least about 50% of “W” towards the other of saidrespective outermost edges of said first and second side portions. 2.The bag of claim 1, said perforations extending a distance of at leastabout 75% of “W.”
 3. The bag of claim 1, said perforations extending adistance of about 100% of “W.”
 4. The bag of claim 1, said perforationsforming a linear pattern that is substantially parallel to at least oneof said respective outermost edges of said first and second endportions.
 5. The bag of claim 1, said bag further comprising a handleadjacent at least one of said first and second end portions.
 6. The bagof claim 5, wherein said handle is at said first end portion.
 7. The bagof claim 5, wherein said handle is integrally formed with said bag. 8.The bag of claim 1, wherein said chamber includes therein a quantity ofa pourable product, said product being selected from the groupconsisting of salt, animal food, flour, sugar, cement, seed, fertilizer,ice, sand, rice, spices, soil, pesticides, industrial chemicals, mortar,plaster, marble dust, and stones.
 9. A method of dispensing a pourableproduct from a bag, the method comprising: providing a bag comprisingfront and back panels each comprising: first and second end portionspresenting respective outermost edges; first and second side portionspresenting respective outermost edges, said front and back panels andsaid end and side portions cooperating to form a chamber for holding thepourable product, there being a width “W,” defined as the shortestdistance between the respective outermost edges of said first and secondside portions; perforations extending from at least one of saidrespective outermost edges of said first and second side portions at adistance of at least about 50% of “W” towards the other of saidrespective outermost edges of said first and second side portions; and aquantity of the pourable product in said chamber; tearing said bag atsaid perforations to form an opening; and causing said pourable productto exit the bag through the opening.
 10. The method of claim 9, saidperforations extending a distance of at least about 75% of “W.”
 11. Themethod of claim 9, said perforations extending a distance of about 100%of
 12. The method of claim 9, said perforations forming a linear patternthat is substantially parallel to at least one of said respectiveoutermost edges of said first and second end portions.
 13. The method ofclaim 9, said bag further comprising a handle adjacent at least one ofsaid first and second end portions.
 14. The method of claim 13, whereinsaid handle is at said first end portion.
 15. The method of claim 13,wherein said handle is integrally formed with said bag.
 16. The methodof claim 9, wherein said pourable product is selected from the groupconsisting of salt, animal food, flour, sugar, cement, seed, fertilizer,ice, sand, rice, spices, soil, pesticides, industrial chemicals, mortar,plaster, marble dust, and stones.
 17. The method of claim 13, furthercomprising gripping said handle while causing said product to exit saidbag.
 18. The method of claim 9, wherein said causing comprises tiltingsaid bag.